Common fault analysis and improvement suggestions: Pneumatic Winch

Pneumatic winches are widely used in mining, shipbuilding, petrochemical and other fields due to their explosion-proof, corrosion-resistant and other characteristics. However, due to the complexity of pneumatic systems and harsh working environments, equipment is prone to malfunctions. The following is a systematic discussion from three aspects: common faults, cause analysis, and improvement suggestions.

1、 Common faults and cause analysis

1. The winch runs weakly or at a slow speed

reason:

Insufficient gas source pressure: The gas source pressure is lower than the rated value (such as<0.6MPa), resulting in insufficient power.

Air leakage: Poor sealing of gas pipes, joints, or valves, resulting in pressure loss.

Decreased motor efficiency: Internal blade wear and bearing jamming in the motor result in a decrease in speed.

Overloading: Exceeding the rated lifting capacity of the winch.

2. Brake failure or delay

reason:

Brake wear: Severe wear of brake pads or discs leads to insufficient friction.

Pneumatic valve malfunction: Brake valve stuck or damaged, unable to respond in a timely manner.

Spring failure: Brake spring fatigue or fracture, resulting in insufficient brake pressure.

3. Abnormal winch noise

reason:

Gear or bearing damage: Poor gear meshing or lack of oil in bearings, resulting in mechanical noise.

Air source impurities: Moisture or particulate matter in the air source enters the motor, causing wear and tear.

Pipeline resonance: Unreasonable design of gas pipeline generates resonance noise.

4. The winch cannot be started

reason:

The gas source is not connected: the gas valve is not open or the gas source is interrupted.

Control valve malfunction: The starting valve or reversing valve is stuck and unable to switch the air path.

Electrical malfunction (if with electronic control): Sensor or solenoid valve damaged.

2、 Improvement suggestions

1. Optimize the gas source system

measures:

Regularly check the pressure of the gas source to ensure that the pressure is stable within the rated range (such as 0.6-0.8MPa).

Install the three components of the air source (filter, pressure reducing valve, oil mist device), filter impurities and lubricate pneumatic components.

Regularly inspect the gas pipeline, replace aging or leaking joints and air pipes.

2. Strengthen the maintenance of the braking system

measures:

Regularly check the wear of brake pads or discs and replace worn parts in a timely manner.

Test the elasticity of the brake spring to ensure that the brake pressure meets the requirements.

Clean the brake valve and check its sealing. If necessary, replace the damaged valve body.

3. Reduce noise and vibration

measures:

Regularly replace gear oil and bearing grease to reduce mechanical wear.

Install a muffler in the air path to reduce exhaust noise.

Optimize pipeline layout, avoid resonance, and increase fixed brackets.

4. Improve control reliability

measures:

Regularly check the flexibility and sealing of control valves (such as directional valves, starting valves).

If equipped with an electronic control system, it is necessary to regularly test the response speed of sensors and solenoid valves.

Add fault alarm devices to monitor real-time parameters such as gas source pressure and temperature.

5. Standardized operation and training

measures:

Develop operating procedures to avoid overloading or frequent starting/stopping.

Train operators to master the key points of equipment maintenance and emergency response measures.

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment